Systems and methods for generating maintenance packages

ABSTRACT

A power plant system includes a turbine system, a sensor, and a controller. The sensor is configured to collect a first set of data regarding the turbine system. The controller is configured to receive user input regarding constraints of the turbine system, a second set of data regarding the power plant system, and the first set of data. The controller is configured to determine whether a first notification is present based on a determined status and to generate a first maintenance package based on the first notification, life odometer solutions, condition monitoring solutions, and the first set of data. The controller is configured to generate a model of implementing the first maintenance package with respect to the turbine system as well as to generate a second maintenance package based on the user input, the second set of data, the first maintenance package, and the scenario model.

BACKGROUND

The subject matter disclosed herein relates to power plants, and morespecifically, to systems and methods for generating maintenance packagesof maintenance operations that can be performed on power plants, as wellas the components within power plants.

Maintenance may be desired or necessary to enhance or repair a powerplant system. To perform certain maintenance operations, the power plantsystem may be shut down to allow maintenance personnel to access variouscomponents within the power plant system. However, the shutdown of thepower plant may cause a decrease in production, revenue, efficiency, andthe like. As such, improved systems and methods for decreasingmaintenance operations are desirable.

BRIEF DESCRIPTION

Certain embodiments commensurate in scope with the originally claimedembodiments are summarized below. These embodiments are not intended tolimit the scope of the claims, but rather these embodiments are intendedonly to provide a brief summary of possible forms of the presentlydisclosed systems and techniques. Indeed, the presently disclosedsystems and techniques may encompass a variety of forms that may besimilar to or different from the embodiments set forth below.

In one embodiment, a power plant system includes a turbine system and asensor. The sensor is configured to collect a first set of dataregarding the turbine system. The power plant system also includes acontroller that includes a processor. Additionally, the controller, viathe processor, is configured to receive user input regarding operatingconstraints of the turbine system, a second set of data regarding thepower plant system from memory, and the first set of data. Thecontroller, via the processor, is also configured to determine a statusof the turbine system based on the first set of data and the second setof data as well as determine whether a first notification is presentbased on the determined status. The controller, via the processor, isfurther configured to map one or more life odometer solutions, one ormore condition monitoring solutions, and the first set of data based onthe first notification. The life odometer solutions include an expectedamount of time before one or more components of the turbine system isrepaired, and the condition monitoring solutions include one or moreconditions of the one or more components. The controller, via theprocessor, is also configured to generate a first maintenance packagebased on the first notification, the life odometer solutions, thecondition monitoring solutions, and the first set of data; the firstmaintenance package includes one or more maintenance activities for thecomponents. The controller, via the processor, is additionallyconfigured to generate a model of implementing the first maintenancepackage with respect to the turbine system based on the user input, thesecond set of data, and the first maintenance package. Furthermore, thecontroller, via the processor, is configured to generate a secondmaintenance package based on the user input, the second set of data, thefirst maintenance package, and the scenario model.

In another embodiment, a method includes receiving, via a processor,user input regarding one or more operating constraints of an industrialasset, a first set of data regarding the industrial asset, and a secondset of data from at least one sensor. The second set of data correspondsto a characteristic of the industrial asset. The method also includesdetermining, via the processor, a status of the industrial asset basedon the first set of data and the second set of data as well asdetermining, via the processor, whether a notification is present basedon the status. The method also includes mapping, via the processor, oneor more life odometer solutions, one or more condition monitoringsolutions, and the at least one sensor based on the notification.Mapping the life odometer solutions includes determining an amount oftime before one or more components of the industrial asset is repaired,and mapping the condition monitoring solutions includes determining acondition of the one or more components. The method also includesgenerating, via the processor, a first maintenance package based on thenotification, the life odometer solutions, the condition monitoringsolutions, and the at least one sensor. The first maintenance packageincludes one or more maintenance activities. Moreover, the methodincludes generating, via the processor, a model of implementing thefirst maintenance package with respect to the industrial asset based onthe user input, the first set of data, and the first maintenancepackage. Furthermore, the method includes generating, via the processor,a second maintenance package based on the user input, the first set ofdata, the first maintenance package, and the model.

In yet another embodiment, a non-transitory machine readable medium,includes computer executable instructions that are configured to cause aprocessor to receive user input regarding one or more operatingconstraints of an industrial asset, a first set of data regarding theindustrial asset, and a second set of data from at least one sensor. Thesecond set of data corresponds to a characteristic of the industrialasset. Also, the computer executable instructions are configured tocause the processor to determine a status of the industrial asset basedon the first set of data and the second set of data as well as determinewhether a first notification is present based on the status. Thecomputer executable instructions are further configured to cause theprocessor to map one or more life odometer solutions, one or morecondition monitoring solutions, and the at least one sensor based on thefirst notification. The life odometer solutions include an amount oftime before one or more components of the industrial asset is repaired,and the condition monitoring solutions comprise a condition of the oneor more components. Moreover, the computer executable instructions areconfigured to cause the processor to generate a first maintenancepackage based on the first notification, the life odometer solutions,the condition monitoring solutions, and the at least one sensor. Thefirst maintenance package includes one or more maintenance activities.Additionally, the computer executable instructions are configured tocause the processor to generate a model of implementing the firstmaintenance package with respect to the industrial asset based on theuser input, the first set of data, and the first maintenance package.Furthermore, the computer executable instructions are configured tocause the processor to generate a second maintenance package based onthe user input, the first set of data, the first maintenance package,and the model.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the presentlydisclosed systems and techniques will become better understood when thefollowing detailed description is read with reference to theaccompanying drawings in which like characters represent like partsthroughout the drawings, wherein:

FIG. 1 is a block diagram of an example combined cycle power plant, inaccordance with embodiments described herein;

FIG. 2 is a data flow chart for generating a maintenance package, inaccordance with embodiments described herein; and

FIG. 3 is a flow chart of a method for generating an updated maintenancepackage, in accordance with embodiments described herein.

DETAILED DESCRIPTION

One or more specific embodiments of the presently disclosed systems andtechniques will be described below. In an effort to provide a concisedescription of these embodiments, all features of an actualimplementation may not be described in the specification. It should beappreciated that in the development of any such actual implementation,as in any engineering or design project, numerousimplementation-specific decisions must be made to achieve thedevelopers' specific goals, such as compliance with system-related andbusiness-related constraints, which may vary from one implementation toanother. Moreover, it should be appreciated that such a developmenteffort might be complex and time consuming, but would nevertheless be aroutine undertaking of design, fabrication, and manufacture for those ofordinary skill having the benefit of this disclosure.

When introducing elements of various embodiments of the presentlydisclosed systems and techniques, the articles “a,” “an,” “the,” and“said” are intended to mean that there are one or more of the elements.The terms “comprising,” “including,” and “having” are intended to beinclusive and mean that there may be additional elements other than thelisted elements.

The present disclosure is generally directed to systems and methods forgenerating maintenance packages of maintenance operations to beconducted on a power plant system and/or components of the power plantsystem. For example, during operation of the power plant system, anotification (e.g., an alarm) related to a status of the power plantsystem and its components may be present. Upon detecting thenotification, a computing system may generate a maintenance package toaddress an issue associated with the notification. For instance, if thenotification is related to an operation of a turbine of the power plantsystem, a maintenance package to remedy an undesirable characteristic ofthe turbine may be generated and presented to a user via a display. Themaintenance package may include, among other things, schedules forperforming corrective and preventative maintenance, specific maintenanceactivities (e.g., replace a specific component of the power plantsystem), and recommendations for how to improve a configuration of thepower plant system in order to reduce the likelihood of performingmaintenance activities at a future time. Additional details with regardto generating maintenance packages will now be discussed with referenceto FIGS. 1-3.

By way of introduction, FIG. 1 is a block diagram of an embodiment of acombined cycle power plant 10 with a controller 12 that may includesystems for generating maintenance packages. The combined cycle powerplant 10 illustrates one example system that may employ the techniquesdescribed herein for generating maintenance packages. However, it shouldbe understood that the presently disclosed techniques may be applied toa variety of systems and should not be limited to combined cycle powerplants.

As shown in FIG. 1, the combined cycle power plant (CCPP) 10 includesthe controller 12, gas turbine system 14, steam turbine system 16, and aheat recovery steam generator (HRSG) 18. In operation, the gas turbinesystem 14 combusts a fuel-air mixture to create torque that drives aload, e.g., an electrical generator. In order to reduce energy waste,the combined cycle power plant 10 uses the thermal energy in the exhaustgases to heat a fluid and create steam in the HRSG 18. The steam travelsfrom the HRSG 18 through a steam turbine system 16 creating torque thatdrives a load, e.g., an electrical generator. Accordingly, the CCPP 10combines the gas turbine system 14 with steam turbine system 16 toincrease power production while reducing energy waste (e.g., thermalenergy in the exhaust gas).

The gas turbine system 14 includes an airflow control module 20,compressor 22, combustor 24, and turbine 26. In operation, an oxidant 28(e.g., air, oxygen, oxygen enriched air, oxygen reduced air, etc.)enters the turbine system 14 through the airflow control module 20,which controls the amount of oxidant flow (e.g., airflow). The airflowcontrol module 20 may control airflow by heating the oxidant flow,cooling the oxidant flow, extracting airflow from the compressor 22,using an inlet restriction, using an inlet guide vane, or a combinationthereof. As the air 28 passes through the airflow control module 20, theair 28 enters the compressor 22. The compressor 22 pressurizes the air28 in a series of compressor stages (e.g., rotor disks 30) withcompressor blades. After the air 28 is pressurized, the pressurized airmay reside in a compressor discharge chamber 29 before the compressedair exits the compressor 22.

After exiting the compressor 22, the compressed air enters the combustor24 and is mixed with fuel 32 after entering the combustor 24. Theturbine system 14 may use liquid or gas fuel, such as natural gas and/ora hydrogen rich synthetic gas, to run the turbine system 14. Forexample, the fuel nozzles 34 may inject a fuel-air mixture into thecombustor 24 in a suitable ratio for optimal combustion, emissions, fuelconsumption, and power output. As depicted, a plurality of fuel nozzles34 intakes the fuel 32, mixes the fuel 32 with air, and distributes theair-fuel mixture into the combustor 24. The air-fuel mixture combusts ina combustion chamber within combustor 24, thereby creating hotpressurized exhaust gases. The combustor 24 directs the exhaust gasesthrough a turbine 26 toward an exhaust outlet 36. As the exhaust gasespass through the turbine 26, the gases contact turbine blades attachedto turbine rotor disks 38 (e.g., turbine stages). As the exhaust gasestravel through the turbine 26, the exhaust gases may force turbineblades to rotate the rotor disks 38. The rotation of the rotor disks 38induces rotation of shaft 40 and the rotor disks 30 in the compressor22. A load 42 (e.g., electrical generator) connects to the shaft 40 anduses the rotation energy of the shaft 40 to generate electricity for useby the power grid.

As explained above, the CCPP 10 harvests energy from the hot exhaustgases exiting the gas turbine system 14 for use by the steam turbinesystem 16 or a boiler. Specifically, the CCPP 10 channels hot exhaustgases 44 from the turbine system 14 into the HRSG 18. In the HRSG 18,the thermal energy in the combustion exhaust gases converts water intohot pressurized steam. The HRSG 18 releases the steam in line 46 for usein the steam turbine system 16.

The steam turbine system 16 includes a turbine 48, shaft 50, and load 52(e.g., electrical generator). As the hot, pressurized steam in line 46enters the steam turbine 48, the steam contacts turbine blades attachedto turbine rotor disks 54 (e.g., turbine stages). As the steam passesthrough the turbine stages in the turbine 48, the steam induces theturbine blades to rotate the rotor disks 54. The rotation of the rotordisks 54 induces rotation of the shaft 50. As illustrated, the load 52(e.g., electrical generator) connects to the shaft 50. Accordingly, asthe shaft 50 rotates, the load 52 (e.g., electrical generator) uses therotation energy to generate electricity for the power grid. As thepressurized steam in line 46 passes through the turbine 48, the steamloses energy (i.e., expands and cools). After exiting the steam turbine48, the steam enters a condenser 49 before being routed back to the HRSG18, where the steam is reheated for reuse in the steam turbine system16.

As explained above, the controller 12 enables the CCPP 10 to flexiblyload the gas turbine system 14, which may enable increased steamproduction in the HRSG 18. The controller 12 may also be employed tocontrol the temperature of the exhaust gas provided to the HRSG 18.

Generally, the controller 12 may include a memory 56 and a processor 58.The memory 56 stores instructions and steps written in software code aswell as data regarding the CCPP 10 and its components. For example, thememory 56 may include instructions and steps for generating amaintenance package for a component or part of the CCPP 10, and thememory 56 may also include stored data regarding operating constraintsand/or the history of the CCPP 10 and/or its components. Morespecifically, the data regarding the history of the CCPP 10 and itscomponents may include data about the maintenance history of the CCPP 10and/or its components as well as data regarding the operations that theCCPP 10 and its components have ever performed. Additionally, the memory56 may include stored data regarding the configuration of the CCPP 10and its components. In other words, the data on the memory 56 mayinclude the layout of the CCPP 10 and its components as well as thearrangement of the components within the CCPP 10. The processor 58executes the stored instructions in response to feedback from the CCPP10. For example, as discussed in detail below, the processor 58 mayexecute the routine for generating and/or updating a maintenancepackage. More specifically, the controller 12 may control andcommunicate with various components in the CCPP 10 to flexibly controlthe loading of the gas turbine system 14, and thus the loading of thesteam turbine system 16. The controller 12 may control the airflowcontrol module 20, the intake of fuel 32, and the valve 47. Thecontroller 12 communicates with load 42, exhaust gas temperature sensor60, HRSG steam temperature sensor 62, and steam turbine metaltemperature sensor 64 to load the CCPP 10 along different load paths.

Although the controller 12 has been described as having the memory 56and the processor 58, the controller 12 may include a number of othercomputer system components to enable the controller 12 to control theoperations of the CCPP 10 and the related components. For example, thecontroller 12 may include a communication component that enables thecontroller 12 to communicate with other computing systems. Thecontroller 12 may also include an input/output component that enablesthe controller 12 to interface with users via a graphical user interfaceor the like.

As discussed below, it should be noted that in some embodiments, thecontroller 12 may monitor the CCPP 10 using the sensors 60, 62, and 64and, via the processor 58, generate a maintenance package partiallybased on the data from the sensors 60, 62, and 64. Although not shown,other sensors may be placed in other suitable parts of the CCPP 10, andthe controller 12 may generate a maintenance package based at leastpartially on the data from the other sensors.

With the foregoing in mind, the routine for generating and/or updating amaintenance package will now be discussed. As noted above, the routinefor generating and/or updating a maintenance package may be stored onthe memory 56 and executed by the processor 58 of the controller 12. Theroutine for generating and/or updating a maintenance package may includeinstructions that assist the processor 58 to generate a maintenancepackage that can be implemented on the CCPP 10 or other suitable system.

The processor 58 may receive input from a user regarding operatingconstraints of the CCPP 10 and/or its components at a present or futuretime. For example, the operating constraints could include a forecastedmission of the CCPP 10 and/or operating conditions such as power output,fuel consumption, and exhaust airflow. The operating constraints mayalso include economic considerations, such as the budgets for conductingpreventative and corrective maintenance as well as potential lostrevenue due to loss of power generation. Furthermore, it should also benoted that the processor 58 may receive data from the sensors 60, 62,and 64 regarding the components of the CCPP 10.

Additionally, in its execution of the routine for generating and/orupdating a maintenance package, the processor 58 may use data stored onthe memory 56 regarding the CCPP 10 and/or its components. For example,the data could include the maintenance history of the CCPP 10 and/or itscomponents as well as data regarding the operations that the CCPP 10 andits components have performed since last undergoing maintenance. Thedata could also include the current status of the CCPP 10 and/or itscomponents. For example, the data may reflect the power output of theCCPP 10, the temperatures of or inside various components of the CCPP10, the fuel consumption of the CCPP 10, and whether the CCPP 10 and itscomponents are operating properly. Furthermore, the data may alsoinclude conditions that trigger various alerts, and the processor 58 maydetermine whether the conditions are still present. The processor 58 canalso generate a corresponding alert based on the conditions that havebeen met.

The data stored on the memory 56 may also include values or ranges ofvalues of typical or expected characteristics of the CCPP 10 based onthe operating conditions of the CCPP 10. For example, the memory couldinclude data regarding expected power outputs, pressure of the oxidantin the compressor 22, temperatures inside the combustor 24, temperaturesof the turbine 26 and many other characteristics of the components ofthe CCPP 10 based on the energy being generated by the load 42. Theprocessor 58 may determine whether a current value for a givencharacteristic is acceptable in comparison to the expected value orrange of values, and thereby recognize whether any anomalies exist.Furthermore, the detected alerts and anomalies may be stored on thememory 56. That is, the data of the memory 56 may include the history ofthe alerts and anomalies associated with the CCPP 10.

Similarly, the data stored on the memory 56 may also includenotifications, which may correspond to various ways by which the CCPP 10may cease to operate properly. In other words, the notifications maycorrespond to certain undesirable conditions of the CCPP 10 and/or itscomponents. For example, one notification may correspond to overheatingin or of the turbine 26. Additionally, the notifications may correspondor relate to the alerts and/or anomalies described above. For example,it could be the case that an alert was previously issued regardingrubbing of one of the rotor disks 38 against the turbine 26 and that atthe present time, the CCPP 10 is no longer operating properly. In theinstant case, there could be a notification that indicates that theimproper operation of the CCPP 10 is due to rubbing of the rotor disk38. In other words, the notifications may correspond to specificundesirable characteristics or conditions of components of the CCPP 10.Moreover, a notification may correspond to a single sensor reading thatis outside of a suitable range of sensor readings, may be triggered byanomalous behavior (i.e. behavior corresponding to an anomaly) or acombination thereof.

The processor 58 may determine the status of the CCPP 10 and itscomponents based on data from the memory and/or data received from thesensors 60, 62, and 64. The processor 58 may then determine whether anotification is present. For example, the processor 58 may receive datafrom the sensor 60 indicating that the exhaust gas exiting the turbine26 is undesirable (e.g., above a temperature threshold). As describedbelow, based on the detected notification, the processor 58 may generatea maintenance package for adjusting the operation of the CCPP 10 toreduce the temperature of the exhaust gas.

With the foregoing in mind, FIG. 2 is a data flow chart 70 of oneembodiment in which the controller 12, via the processor 58, maygenerate a maintenance package. Before discussing the data flow chart 70in greater detail, it should be noted that the data flow chart 70 may beutilized by any suitable computing device, not just the controller 12.Moreover, although the data flow chart 70 is described as taking placein particular order, it should be understood that the data flow chart 70may be executed in any suitable order. Additionally, the controller 12,via the memory 56, may include a maintenance routine system 78, themaintenance routine system 78 may include n notification conditionanalyzer 80, and user input 72, sensor data 74, and data constraints 76may be received by the maintenance routine system 78 via thenotification condition analyzer 80. It should be noted that themaintenance routine system 78 may not be stored on the memory 56 inother embodiments. Instead, the maintenance routine system 78 may bestored elsewhere (e.g., a cloud and/or other memory) and used by thecontroller 12. As described below the maintenance routine system 78 may,among other things, generate maintenance packages, simulate scenariomodels of the generated maintenance packages, and compare the scenariomodels to known or previously utilized maintenance packages.

Referring now to FIG. 2, the notification condition analyzer 80 mayreceive the user input 72 regarding operating constraints of anindustrial asset (e.g., the CCPP 10) and/or its components. Theoperating constraints may include ranges of values (e.g., temperature,voltage, current, flow, pressure, cost) that correspond to expectedoperating conditions of various components of the CCPP 10 (e.g., aforecasted mission of the CCPP 10). As discussed above, theseconstraints may presently exist or may be potentially implemented at afuture time. Moreover, the constraints may be based on many factors suchas, but not limited to, power output of the CCPP 10 and/or economicconsiderations (e.g., budgets for preventative and correctivemaintenance). For example, the user input 72 may include forecastedoperations of the industrial asset, expected penalties associated withwhen the industrial asset is not operating, and budgets for performingmaintenance on the industrial asset. In the example of the CCPP 10, theforecasted operations may include, but are not limited to, power output,the amount of time the CCPP 10 will be generating power, and efficiency.The penalties associated with when the CCPP 10 is not operating couldinclude a decrease in potential income and the amount of time that theCCPP 10 is not operating. As discussed above, the budgets for performingmaintenance may include budgets for preventative and correctivemaintenance.

The notification condition analyzer 80 may also receive the sensor data74. The sensor data may include various information regarding theindustrial asset of which the sensors are disposed or associated with.Continuing with the example of the CCPP 10, the sensor data 74 mayinclude temperature data from the sensors 60, 62, and 64. It should benoted, however, that the sensor data 74 may include other types of data.For instance, the CCPP 10 may include other sensors (e.g., pressuresensors), and the other sensors may provide the sensor data 74 to thecontroller 12.

Additionally, the notification condition analyzer 80 may receive thedata constraints 76 of the industrial asset. The data constraints 76 maybe stored on the memory 56. The data constraints 76 may include thehistory of the industrial asset (e.g., operations performed by theindustrial asset and maintenance operations performed on the industrialasset), the configuration of the industrial asset, and alerts and/oranomalies. In the example of the CCPP 10, the history of the CCPP 10 mayinclude the operational history of the CCPP 10 since maintenance waslast performed on the CCPP 10. For instance, the operational historycould include power output, prior sensor data, and when the lastmaintenance operation was performed. The configuration may include thehardware and software of the CCPP 10. In other words, the configurationmay reflect the components of the CCPP 10 and the location of thecomponents within the CCPP 10. The configuration may also reflect thesoftware that is installed on or utilized by the CCPP 10 and thecomponents of the CCPP 10. Furthermore, the alerts and anomalies may bepredefined and/or include conditions that may be met in order for anotification to be issued. For example, the memory 56 may contain a setof conditions related to the turbine 26, such as a range of temperaturessensed by the sensor 60. If a temperature is not within the range, thenan anomaly may be present. Moreover, the memory 56 may containinstructions to issue an alert when an anomaly in the temperature sensedby the sensor 60 is detected.

Turning now to the maintenance routine system 78, the notificationcondition analyzer 80 may utilize the sensor data 74 and the dataconstraints 76 to determine whether any notifications are present. Withthis in mind, the discussion will now turn to how the notificationcondition analyzer 80 may make such a determination.

Based on the sensor data 74 and the data constraints 76, thenotification condition analyzer 80 may determine a baseline of theindustrial asset. The baseline may include the components of theindustrial asset and the condition of the components. In other words,determining the baseline may include determining the components of theindustrial asset, as well as the conditions of those components. Forexample, in the context of the CCPP 10, the notification conditionanalyzer 80 may receive the sensor data 74 and the data constraints 76.The data constraints may include configuration of the CCPP 10, as wellas the operational settings of the CCPP 10 and the components of theCCPP 10. The notification condition analyzer 80 may determine orestimate the condition of the components based on the data constraints76 and the sensor data 74. For instance, a component of the CCPP 10(e.g., one of the rotor disks 38) may be expected to properly functionfor a certain amount of time before it may be desirable to replace thecomponent, and the data constraints 76 may include information regardingwhen the rotor disk 38 was last replaced. Thus, the condition of therotor disk 38 at a given time may be estimated based on the amount oftime that the rotor disk 38 is expected to function properly and theamount of time that has passed since the rotor disk 38 was added to theCCPP 10.

Moreover, the sensor data 74 may also be utilized to estimate thecondition of the components of the CCPP 10. For example, a sensor maydetect an unfavorable condition (e.g., excessive temperature) thatreduces the amount of time a component associated with the sensor isexpected to function before being replaced. Based on the sensor data 74,which corresponds to the detected unfavorable condition, and the amountof time the component the component was expected to function properlybefore being replaced (which can be determined in the manner discussedabove in this paragraph), the maintenance routine system 78 may estimatethe condition of the component. For example, referring to the CCPP 10, asensor may detect rubbing of a rotor disk 38 against the turbine 26.However, based on the extent of the rubbing, the turbine 26 or the rotordisk may need to be replaced earlier than previously expected. It may bethe case that the rotor disk 38 should be replaced immediately.

The baseline may also include a status of the industrial asset. Forinstance, the notification condition analyzer 80 may determine a statusthat reflects that the conditions of a notification are present.Continuing with the example of the CCPP 10, the baseline may include anotification for rubbing of the rotor disks 38 against the turbine 26.More specifically, the notification condition analyzer 80 may determinethat predefined conditions for a notification indicative of rubbing ofthe rotors disks 38 against the turbine 26 are present.

If conditions for at least one notification are present, thenotification condition analyzer 80 may map life odometer solutions,condition monitoring solutions, and sensors of the industrial assetbased on the notification or notifications that exist. Mapping the lifeodometer solutions may include determining the life limit of thecomponents of the industrial asset. The life limit refers to the actualand/or expected longevity of a given component. For example, the lifelimit could be based on the number of times the industrial asset isstarted and stopped or the amount of time a component of the industrialasset is used. It should also be noted that the life limit could bebased on more than one factor. For example, the life limit could bebased on both the number of times the industrial asset is stopped andstarted as well as the amount of time the component is used. A lifeodometer solution may correspond to a life limit. For example, the lifelimit solution may note that a certain component may most likely be usedanother 5,000 hours before it should be serviced or replaced.Furthermore, mapping the life odometer solutions may include determiningthe life limit of the components of the industrial asset based on anevent probability and potential consequence of the event. The eventprobability may correspond to the likelihood of an undesirable eventtaking place (e.g., improper functioning a component of the industrialasset), and the potential consequence may be a result of the eventoccurring or correspond to a probability of the potential consequenceoccurring if the event occurs. For instance, the potential consequencemay be improper or undesirable functioning of the industrial assetcaused as a result of an undesirable event taking place. Moreover, itshould be noted that there could be any number of life odometersolutions. Thus, the mapping of the life odometer solutions may alsoinclude determining and/or compiling all of the individual life odometersolutions of any or all of the components of the industrial asset.

Mapping the condition monitoring solutions may include determining thecondition of the industrial asset and/or the condition of the componentsof the industrial asset. For instance, referring to the example of theCCPP 10, the condition of one rotor disk 38 may not meet a certaindesirable condition. A condition monitoring solution based on thecondition of the rotor disk 38 may be generated, via the processor 58,based on the condition of the rotor disk 38. For example, in a scenarioin which the rotor disk 38 is damaged, the condition monitoring solutionmay suggest that the sustained damage is life limiting. In other words,the condition monitoring solution may recommend that the CCPP 10 cannotoperate properly with the damaged rotor disk 38. However, in anotherscenario in which the rotor disk 38 may be in a less than desirablecondition but may still be used while the CCPP 10 is running, thecondition monitoring solution may indicate that the rotor disk 38 couldstill be used. Moreover, there may be any number of condition monitoringsolutions. Thus, the mapping of the condition monitoring solutions mayalso include determining and/or compiling all of the individualcondition monitoring solutions of any or all of the components of theindustrial asset.

Mapping the sensors may include determining whether the data fromsensors of the industrial asset may reflect or suggest any abnormal orundesirable conditions. Returning to the example of the CCPP 10, it maybe the case that the sensor 60 may reflect that the exhaust exiting theturbine 26 has an undesirable temperature. In other words, mapping thesensors may include determining whether any alerts should be or shouldhave been issued and whether any abnormalities are or were present.

Based on the determined notification(s), mapped life odometer solutions,mapped condition monitoring solutions, and mapped sensors, a maintenancepackage generator 82 may generate an initial maintenance package. Theinitial maintenance package may include suggested preventative andcorrective maintenance schedules and/or operations. For example, in thecase of the CCPP 10, if a notification indicative of an undesirablecharacteristic of one of the rotor disks 38 were present, themaintenance package generator 82 may generate an initial maintenancepackage suggesting that the rotor disk 38 be repaired or replaced. Itshould be noted that the initial maintenance package may also suggestactions to take. For instance, returning to the example of the CCPP 10,if the initial maintenance package were to suggest shutting down theCCPP 10 in order to perform a maintenance activity and the user does notwish to shut down the CCPP 10, the initial maintenance package maysuggest another course of action (e.g., run the CCPP 10 such that thetemperature of the exhaust of turbine 26 is lower). The other course ofaction may also include performing a different maintenance activity. Forexample, instead of servicing a damaged component, the other course ofaction may suggest replacing the component. Additionally, as discussedbelow, the initial maintenance package may include several types ofoutages for the industrial asset. For instance, the initial maintenancepackage could recommend shutting down the industrial asset at a certaintime in the future in order to perform maintenance activities.

Furthermore, the initial maintenance package may include an equipmentconfiguration. The equipment configuration may include changes to theconfiguration of the industrial asset that may improve the likelihood ofreducing the number or cost of future maintenance activities. Forinstance, in the example of the CCPP 10, the equipment configuration mayinclude adding a sensor in order to provide more data regarding acomponent of the CCPP 10 (e.g., the compressor 22, the combustor 24, orthe turbine 26). The additional data provided by the added sensor mayallow for earlier detection of anomalies, and earlier detection ofanomalies may result in earlier detection of notifications. Earlierdetection of notifications may reduce the costs of maintenanceassociated with the notifications. Additionally, the equipmentconfiguration may include operational settings of the components of theindustrial asset that may extend the expected life limit of thecomponents. In the case of the CCPP 10, the equipment configuration mayinclude, among other things, changing operating settings related to theturbine 26 in order to reduce the temperature of the exhaust that exitsthe turbine. As another example, the equipment configuration may includeoperating settings that reduce the rate at which the rotor disks 38operate.

A scenario model simulator 84 may receive the initial maintenancepackage generated by the maintenance package generator 82. The scenariomodel simulator 84 may also simulate the effect of using the initialmaintenance package. For example, the scenario model simulator 84 mayevaluate the potential result of performing the initial maintenancepackage. In other words, the initial maintenance package could recommenda certain course of action, and the scenario model simulator 84 maysimulate what effect performing the initial maintenance package wouldhave on the industrial asset and the components of the industrial asset.

More specifically, the memory 56 may contain data representative of theindustrial asset, such as a virtual model of the industrial asset. Whena notification is determined, the conditions (e.g., sensors data)associated with the notification may be incorporated into the virtualmodel of the industrial asset. Furthermore, the initial maintenancepackage from the maintenance package generator 82 may be simulated inthe virtual model of the industrial asset via the scenario modelsimulator 84. Thus, the scenario model of the initial maintenancepackage may include an expected outcome of performing the initialmaintenance package. In other words, by implementing the initialmaintenance package on the virtual model of the industrial asset, thescenario model simulator 84 may generate a scenario model that reflectsthe expected effect the initial maintenance package will have on theindustrial asset and its components. For example, the scenario modelcould be used to determine whether the initial maintenance package willlikely or actually remedy an issue associated with the industrial assetor its components, and the scenario model may also reflect the expectedchanges to characteristics or qualities of the industrial asset (e.g.,efficiency). Furthermore, the scenario model of the initial maintenancepackage may also simulate other factors related to the industrial asset.For example, the scenario model may be used to model the approximatecost to perform the initial maintenance package.

The scenario model simulator 84 may also simulate the initialmaintenance package based on other industrial assets and/or themaintenance histories of the other industrial assets. For instance, withthe example of the CCPP 10 in mind, the scenario model simulator 84 maysimulate the effect of implementing the initial maintenance package onthe CCPP 10 by simulating the effect of implementing the maintenancepackage on a different power plant. Additionally, a simulation of theinitial maintenance package on the other power plant may take intoconsideration the maintenance history of the other power plant. Forexample, it may be the case the notification present in the CCPP 10 waspreviously present in the other power plant. The scenario modelsimulator 84 may then use data (e.g., from the memory 56) what was doneto the other power plant (e.g., a maintenance activity), in itssimulation of the scenario model of implementing the initial maintenancepackage in the CCPP 10.

The scenario model generated by the scenario model simulator 84 may bereceived by a maintenance learning system 86. Based on the user input 72and the data constraints 76, the maintenance learning system 86 maycheck the scenario model to determine whether the scenario model may bechanged to better conform to the user input 72 and data constraints 76.For instance, the scenario model generated by the scenario modelsimulator 84 may suggest that the initial maintenance package includes amaintenance activity that conflicts with the user input 72. An exampleof this may be that the scenario model suggests a preventativemaintenance operation that will exceed the preventative maintenancebudget. Moreover, the maintenance learning system 86 may determinewhether more initial maintenance packages should be generated by themaintenance package generator 82. For example, the scenario model of theinitial maintenance package received by the maintenance learning system86 may accord with the user input 72 and the data constraints 76, but itmay be possible that another initial maintenance package may be moresuitable. For instance, it may be possible that another initialmaintenance package would have the same effect as the initialmaintenance package but increase the efficiency of the industrial assetand/or suggest a maintenance operation that is less costly and/or can beperformed in less time than the initial maintenance package. As such,the maintenance learning system 86 may send a command to the maintenancepackage generator 82 to generate another initial maintenance package,which may subsequently be simulated by the scenario model simulator 84and checked by the maintenance learning system 86. This cycle may repeata number of times until the scenario model simulator 84 produces resultswithin a desired threshold.

Similar to the scenario model simulator 84, the maintenance learningsystem 86 may also check the scenario model of the initial maintenancepackage against other industrial assets and/or the maintenance historiesof the other industrial assets. For instance, the maintenance learningsystem 86 may compare the scenario model of the initial maintenancepackage with the same or a similar maintenance package that wasperformed on another industrial asset to determine the validity of thescenario model. For example, in the case of the CCPP 10, the maintenancelearning system 86 may compare the scenario model to a maintenancepackage that was performed on another power plant and determine thelikely accuracy of the scenario model. For instance, the maintenancelearning system 86 may determine that the maintenance costs predicted inthe scenario model are inaccurate based on the known cost of themaintenance package previously performed on the other power plant. As afurther example, the maintenance learning system 86 may determine thatthe scenario model is accurate in its predicted effect of performing theinitial maintenance package (i.e., determining whether performing theinitial maintenance package will make the expected change(s) to the CCPP10).

Moreover, the maintenance learning system 86 may compare the scenariomodel generated by the scenario model simulator 84 to data regardingother industrial assets in order to determine the validity of thenotification generated by the notification condition analyzer 80. In thecase of the CCPP 10, the maintenance learning system 86 may read in data(e.g., from the memory 56) regarding notifications issued by other powerplants, sensor data from other power plants, and the maintenance historyof the other power plants. The maintenance learning system 86 maycompare the scenario model to the actual data from the other plants toverify the validity of the notification present in the CCPP 10. Forexample, it may be the case in another power plant that sensor datasimilar to the sensor data 74 was recorded, yet a different notificationwas determined to be present. The maintenance learning system 86 maysend a command to the notification condition analyzer 80 to reexamine ifthe originally determined notification and/or another notification ispresent. The notification condition analyzer 80 may make thisdetermination, the maintenance package generator 82 may generate aninitial maintenance package based on the notification determined to bepresent, the scenario model simulator 84 may simulate the initialmaintenance package to generate a scenario model, and the scenario modelmay be further examined by the maintenance learning system 86. All ofthese tasks may be performed in the manner described above. Such a cyclemay be repeated any number of times.

The maintenance routine system 78 may determine an updated maintenancepackage 88. The updated maintenance package 88 may contain theinformation of an initial maintenance package generated by themaintenance package generator 82 as described above. The updatedmaintenance package 88 may be the initial maintenance package that hasbeen modified or the updated maintenance package 88 may be differentmaintenance package. More specifically, the updated maintenance package88 may be an initial maintenance package generated by the maintenancepackage generator 82 that has subsequently been simulated by thescenario model simulator 84 and checked by the maintenance learningsystem 86. Thus, the updated maintenance package 88 may includesuggested preventative and corrective maintenance schedules and/oroperations, actions to take (e.g., run the CCPP 10 such that thetemperature of the exhaust of turbine 26 is lower), outages for theindustrial asset, and an equipment configuration. It should be notedthat the updated maintenance package 88 may be a maintenance packagethat meets the constraints of the user input 72 and the data constraints76 and corresponds to the sensor data 74. Thus, the updated maintenancepackage 88 may be a maintenance package that, if performed, may allowthe industrial asset to perform the forecasted operations, have a lowerpotential loss of income due to downtime in comparison to othermaintenance packages, and have a maintenance schedule that is less thanor equal to the preventative maintenance and corrective maintenancebudgets. Additionally, the maintenance schedule of the updatedmaintenance package 88 may include maintenance operations that are morecost effective to perform than maintenance operations of othermaintenance packages, yet the updated maintenance package 88, ifperformed, may also extend the predicted life limit of the components ofthe industrial asset.

Furthermore, the updated maintenance package 88 may be output ordisplayed to a user, for example, via a graphical user interface ordisplay associated with the industrial asset (e.g., the controller 12 orthe CCPP 10). Additionally, the updated maintenance package 88 may bedisplayed in various formats. For example, the updated maintenancepackage 88 may include letters or numbers. In other words, the updatedmaintenance package 88 may include words or sentences that detail whatthe updated maintenance package 88 is and/or includes. For example, theupdated maintenance package 88 could be displayed as sentences detailingthe steps that should be taken by the user to perform the updatedmaintenance package 88, and those steps could include numbers (e.g.,numeric values related to settings of the components of the CCPP 10). Asa further example of how the updated maintenance package 88 may bedisplayed, the updated maintenance package 88 may also include gauges orcolor shading or color gradations, or any combination thereof. Forexample, the updated maintenance package 88 could display a gauge thatreflects a characteristic of a component of the CCPP 10 (e.g.,percentage of expected life limit of a component of the CCPP 10 that hasbeen used or remains). Similarly, color shading or color gradations mayalso be used. For example, colors may be used to notify the user of thecomponents for which a notification has been determined to exist. Forinstance, if a notification associated with the turbine 26 is determinedto exist, the displayed updated maintenance package 88 could include adigital representation of the CCPP 10, and the turbine 26 may berepresented in a different color than the other components of the CCPP10. Color gradations may also be used. For example, the displayedupdated maintenance package 88 may include digital representation of theCCPP 10, and each component of the CCPP 10 may be presented in a shadeof a color that is representative of a characteristic of each feature(e.g., shades of a color reflective of remaining time before expectedlife limit is reached or maintenance should be performed).

A maintenance management system 90 may receive the updated maintenancepackage 88, and the maintenance management system 90 may implement atleast some of the updated maintenance package 88 on the industrialasset. Moreover, the maintenance management system 90 may also trackupdated maintenance packages 88. In other words, the maintenancemanagement system 90 may determine the extent to which the updatedmaintenance package 88 has been performed. The maintenance managementsystem 90 may display information about the updated maintenance packageand/or the status of the implementation of the updated maintenancepackage in the same ways as discussed above in relation to how theupdated maintenance package may be displayed. Additionally, themaintenance management system 90 may generate and display notices basedon the life odometer solutions, condition monitoring solutions, thesensor data 74 or a combination thereof. For example, the maintenancemanagement system 90 may generate a notice based on the life odometersolutions that a new maintenance package should be generated. Moreover,the maintenance management system 90 may be a program executable by thecontroller 12 or a computer. The maintenance management system 90 may bestored on the memory 56 or in another suitable location (e.g., anothermemory).

Furthermore, the maintenance management system 90 may send data relatedto the updated maintenance package 88 to be included in the dataconstraints 76. For example, the maintenance management system 90 maysend data that includes information regarding the updated maintenancepackage 88 and/or the status of the implementation of the updatedmaintenance package 88 to the memory 56, which may then store the datawith the data constraints 76. As a further example, once the maintenanceoperations or maintenance schedule of the updated maintenance package 88has been performed, the data constraints 76 may reflect when themaintenance operations or maintenance schedule was performed. Thus, theoperations done since the last maintenance operation, which as discussedabove may be included in the data constraints 76, may reflect theoperations performed since the maintenance operations or the maintenanceschedule of the updated maintenance package 88 was performed.

It is to be appreciated that the updated maintenance package 88 may bemodified and/or another updated maintenance package 88 may be generatedbased on changes to the user input 72, the sensor data 74, and the dataconstraints 76. In other words, the maintenance routine system 78 maydynamically change or replace the updated maintenance package 88 inresponse to changes in the user input 72, the sensor data 74, and thedata constraints 76. Going back to the example of the CCPP 10, theupdated maintenance package 88 may have included specific maintenanceactivities, and the maintenance activities may have been performed.Subsequent to the performance of the maintenance activities, the sensordata 74 may change (i.e., the sensor 60 may reflect an undesirabletemperature whereas the sensor 60 has previously reflected that thetemperature was suitable). Following along FIG. 2 as described above,the maintenance routine system 78 may then determine and output another(i.e., a second) updated maintenance package 88 and/or modify theupdated maintenance package 88 based in part on the sensor data 74.Additionally, the updated maintenance package 88, as modified, or thesecond preferred maintenance package 88 may subsequently be sent to themaintenance management system 90, which may then carry out the tasksassociated with the maintenance management system 90 described above.Thus, the maintenance routine system 78 may continuously and dynamicallymodify an existing updated maintenance package or generate a new updatedmaintenance package based on changes to the user input 72, the sensordata 74, or the data constraints 76.

It should also be noted that the updated maintenance package 88 may bemodified and/or another updated maintenance package 88 may be generatedbased on changes to the user input 72, the sensor data 74, and the dataconstraints 76 even when a notification is not present. For instance, auser may change the user input 72 to reflect different forecastedoperations of the industrial asset or a different budget forpreventative and/or corrective maintenance. In such a case, the updatedmaintenance package 88 may be modified and/or another updatedmaintenance package may be generated. For example, in the case of theCCPP 10, the user input 72 may be changed to include a desired poweroutput that is higher than the power output originally included in theuser input 72, and the updated maintenance package 88 may be updated orreplaced. For instance, the originally updated maintenance package 88may be treated as an initial maintenance package generated by themaintenance package generator 82. The original updated maintenancepackage 88 may then be simulated by the scenario model simulator 84 togenerate a scenario model. The scenario model may be checked by themaintenance learning system 86, which may recognize that the user input72 has changed. Thus, as described above, the maintenance learningsystem 86 may send a command to the maintenance package generator 82 togenerate an initial maintenance package. Such a process, or any processdescribed above in relation to the maintenance routine system 78, may becarried out until a new or modified updated maintenance package 88 isgenerated.

With the foregoing in mind, FIG. 3 illustrates a method 100 forgenerating an updated maintenance package 88 that will now be described.Although the following description of the method 100 will be discussedas being performed by the controller 12, it should be noted that themethod 100 may be performed by any suitable computing device. Moreover,although the method 100 is described as being performed in a particularorder, it should be understood that the method 100 may be performed inany suitable order. It should also be emphasized that although thefollowing discussion of the method 100 is in relation to the CCPP 10,the method 100 may be performed on a variety of other systems.

Referring now to FIG. 3, at block 102, the controller 12 may receiveuser input regarding operating constraints of the CCPP 10 and/or itscomponents. The operating constraints may include ranges of values(e.g., temperature, voltage, current, flow, pressure) that correspond toexpected operating conditions of various components of the CCPP 10. Asdiscussed above, these constraints may presently exist or may bepotentially implemented at a future time. Moreover, the constraints maybe based on a plethora of factors such as power output of the CCPP 10and/or economic considerations (e.g., budgets for preventative andcorrective maintenance).

At block 104, the controller 12 may receive data constraints from thememory 56 regarding the CCPP 10 and its components. As discussed above,the data may include the maintenance history of the CCPP 10 and/or itscomponents. Additionally, the data may include information regarding theoperations that the CCPP 10 and its components have performed since lastundergoing maintenance and whether any alerts or anomalies have beenissued or detected since the previous maintenance operation. The datamay also include information regarding a prior status of the CCPP 10 orits components.

Additionally, at block 106, the processor 58 may receive data from thesensors 60, 62, and 64 regarding components of the CCPP 10. The datafrom the sensors 60, 62, and 64 may provide details with regard to thecurrent operating conditions of the respective components.

At block 108, the controller 12 may determine the status of thecomponents of the CCPP 10 and the CCPP 10 based on the data from thememory 56 and the data from the sensors 60, 62, and 64. For example, asdescribed above, the controller 12 may determine that the CCPP 10 andall of its components are operating properly. Additionally, thecontroller 12 may determine that the CCPP 10 is not running properly oras desired. As a further example, a sensor may detect an unfavorablecondition that reduces the expected life limit of a rotor disk 38. Basedon the data from the sensor, which corresponds to the detectedunfavorable condition, and the expected life limit of the rotor disk 38before the unfavorable condition occurred (which may be included in thedata stored on the memory 56), a new life limit, which reflects thecondition of the rotor disk 38, may be determined. For example, the datafrom the sensor may reflect that the rotor disk has undergone damage andthat before the damage occurred, the life limit was 5,000 hours.Depending on the severity of the damage, the new life limit may be anamount of time less than 5,000 hours.

After determining the status of the components, at block 110, thecontroller 12 may determine whether a notification is present based onthe status of the components. For example, if the CCPP 10 and all of itscomponents are operating properly and/or as desired, then the processor58 may determine that no notification is present. If the controller 12determines that the notification is not present, the controller 12 mayreturn to block 104 and continue to receive data from the memory 56regarding the status of the CCPP 10 and/or its components.

However, based on the status of the components, the controller 12 maydetermine a notification is present. As discussed above, thenotification may be specific to one or more components of the CCPP 10.For example, there may be an notification indicating that the turbine 26or one of the rotor disks 38 is not operating properly (e.g.,overheating or rubbing exists).

If the controller 12 determines a notification is present, at block 112,the controller 12, via the processor 58, may map life odometersolutions, condition monitoring solutions, and the sensors 60, 62, and64 based on the determined notification. Mapping the life odometersolutions may include determining the life limit of the components ofthe CCPP 10. The life limit refers to the actual and/or expectedlongevity of a given component. For example, the life limit could bebased on the number of times the CCPP 10 is started and stopped or theamount of time the component is used. It should also be noted that thelife limit could be based on more than one factor. For example, the lifelimit could be based on both the number of times the CCPP 10 is stoppedand started as well as the amount of time the component is used. A lifeodometer solution may correspond to a life limit. For example, the lifelimit solution may note that a certain component may most likely be usedanother 5,000 hours before it needs to be serviced or replaced.Moreover, it should be noted that there could be any number of lifeodometer solutions. Thus, the mapping of the life odometer solutions mayalso include determining and/or compiling all of the individual lifeodometer solutions of any or all of the components of the CCPP 10.

Mapping the condition monitoring solutions may include determining thecondition of the CCPP 10 and/or its components. For instance, thecondition of one rotor disk 38 may not meet a certain desirablecondition. A condition monitoring solution based on the condition of therotor disk 38 may be generated, via the processor 58, based on thecondition of the rotor disk 38. For example, in a scenario in which therotor disk 38 is damaged, the condition monitoring solution may suggestthat the sustained damage is life limiting. In other words, thecondition monitoring solution may recommend that the CCPP 10 cannotoperate properly with the damaged rotor disk 38. However, in anotherscenario in which the rotor disk 38 may be in a less than desirablecondition but may still be used while the CCPP 10 is running, thecondition monitoring solution may reflect that the rotor disk 38 couldstill be used. Moreover, it there may be any number of conditionmonitoring solutions. Thus, the mapping of the condition monitoringsolutions may also include determining and/or compiling all of theindividual condition monitoring solutions of any or all of thecomponents of the CCPP 10.

Mapping the sensors may include determining whether the data from thesensors 60, 62, and 64 may reflect or suggest any abnormal orundesirable conditions. For example, the sensor 60 may reflect that theexhaust exiting the turbine 26 has an undesirable temperature. In otherwords, mapping the sensors may include determining whether any alertsshould be or should have been issued and whether any abnormalities areor were present.

As an example to further demonstrate what may occur at block 112,consider a scenario in which at a determined notification reflects thatat least one of the rotor disks 54 has an undesirable condition due toan unsuitable temperature within the turbine 48. A life odometersolution may reflect how much longer each of the rotor disks 54 can beexpected to be used before needing to be replaced. A conditionmonitoring solution may reflect that some of the rotors disks 54 are ingood condition but that at least one of the rotor disks 54 has lifelimiting damage (e.g., one of the rotor disks 54 should not be used morethan a certain amount of time before being replaced). The mapping of thesensors 60, 62, and 64 may reflect that the turbine 48 has beenoperating at too high of a temperature.

Based on the life odometer solutions, the condition monitoringsolutions, and the data from the sensors, at block 114, the controller12, via the processor 58, may generate an initial maintenance package.The initial maintenance package may include suggested preventative andcorrective maintenance schedules and/or operations. Continuing with theexample of the rotor disk 54 from above, the initial maintenance packagemay include specific maintenance tasks that should be performed suchthat, once performed, the notification will be no longer present. Theinitial maintenance package may also direct a user as to when the nextpreventative maintenance should be carried out on any of the componentsof the CCPP 10, including the turbine 48 and/or the rotor disks 54.

The initial maintenance package may also suggest actions to take. Forexample, if the initial maintenance package suggests shutting down theCCPP 10 in order to perform a maintenance activity and the user does notwish to shut down the CCPP 10, the initial maintenance package maysuggest another course of action (e.g., run the CCPP 10 such that thetemperature of the exhaust of turbine 26 is lower). The other course ofaction could also include performing a different maintenance activity.For example, instead of servicing a damaged component, the other courseof action may suggest replacing the component.

Additionally, the initial maintenance package may include several typesof outages for the CCPP 10. For example, the initial maintenance packagecould include a planned outage, a maintenance outage, or a forcedoutage. A planned outage may be suggested for many reasons, includingperforming diagnostics related to the notification. For example, if ageneral notification is determined to be present (e.g., a notificationspecific to the turbine 26 instead of one specific to one of the rotordisks 38), the initial maintenance package may suggest scheduling aplanned outage during which workers may determine the specific cause asto why the notification is present. A maintenance outage may besuggested, during which workers will perform suggested maintenanceactivities. For example, the initial maintenance package may recommendscheduling routine maintenance at a given time in the future duringwhich time the initial maintenance package recommends making a repair. Aforced outage may be an outage due to an unscheduled interruption in thepower generation of the CCPP 10. For example, a component of the CCPP 10may unexpectedly cease operating properly, causing the CCPP 10 to stopoperating, and hence, cause a forced outage. The initial maintenancepackage may be based on n notification that is present due to a forcedoutage.

Based on the generated initial maintenance package, the data from thememory 56, and the user input, at block 116, the controller 12 maygenerate a scenario model of the initial maintenance package. Morespecifically, the scenario model of the initial maintenance package maybe used to determine or evaluate a potential result of performing theinitial maintenance package and/or other related information. Forexample, the initial maintenance package could recommend a certaincourse of action, and the scenario model of the initial maintenancepackage may simulate what effect performing the initial maintenancepackage would have on the CCPP 10 and its components. More specifically,the memory 56 may contain stored data representative of the CCPP 10,such as a virtual model of the CCPP 10. When n notification isdetermined, the notification may be incorporated into the virtual modelof the CCPP 10. Furthermore, the generated initial maintenance packagemay be simulated in the virtual model of the CCPP 10. Thus, the scenariomodel of the initial maintenance package may include an expected outcomeof performing the initial maintenance package. In other words, byimplementing the initial maintenance package on the virtual model of theCCPP 10, the controller 12, via the processor 58, may generate ascenario model that reflects the expected effect the initial maintenancepackage will have on the CCPP 10 and its components. For example, thescenario model could be used to determine whether the initialmaintenance package will likely or actually remedy an issue associatedwith the CCPP 10 or its components, and the scenario model may alsoreflect the expected changes to characteristics or qualities of the CCPP10 (e.g., efficiency, power output, etc.). Furthermore, the scenariomodel of the initial maintenance package may also simulate other factorsrelated to the CCPP 10. For example, the initial scenario model may beused to model the approximate cost to perform the maintenance package.

Moreover, the scenario modeling of the initial maintenance package mayincorporate operational data and/or components of other power plants.For example, the memory 56 may contain data regarding other powerplants, maintenance packages performed at the other power plants, andthe result of the maintenance packages implemented at the other powerplants (e.g., whether an notification was eliminated, cost, poweroutput, downtime, etc.). In addition to the factors described above, thescenario modeling may also include modeling based on the other powerplants. For example, if the initial maintenance package recommendedreplacing a rotor disk 54, the scenario modeling of the initialmaintenance package could include determining whether the rotor disk 54of another turbine 48 in another power plant had been replaced, and thenbase a cost estimate and/or downtime needed to perform the maintenanceon the cost of replacing and time needed to replace the rotor disk 54.

Based on the user input, the data constraints, the initial maintenancepackage, and the scenario model of the initial maintenance package, atblock 118, the controller 12 may generate an updated maintenance package88. The updated maintenance package 88 may be generated after thescenario model of the initial maintenance package is further analyzed orchecked by the controller 12. The controller 12 may analyze or check thescenario model as a function of many factors, including but not limitedto, budgets for maintenance, expected lost revenue from loss of powergeneration, the amount of time that has passes since the last performedmaintenance, and downtime. Moreover, the many factors may also beassigned different weights. In other words, some factors may be givenmore importance than others.

Moreover, as discussed above, the updated maintenance package 88 mayinclude any of the features or details discussed above in relation toinitial maintenance packages. Thus, the updated maintenance package 88may include suggested preventative and corrective maintenance schedulesand/or operations such as specific maintenance tasks that should beperformed, when the next preventative maintenance should be carried outon any of the components of the CCPP 10, and actions to take (e.g., shutdown the CCPP 10 or replace a component of the CCPP 10).

It should be noted that the more than one notification may be determinedto exist. In such an event, the life odometer solutions, conditionmonitoring solutions, and the sensors 60, 62, and 64 may be mapped basedon the more than one notifications. Additionally, a maintenance packagemay be based on more than one notification.

It should also be noted that any examples given are only given toillustrate the abilities of the routine for generating and/or updating amaintenance package. The routine for generating and/or updating amaintenance package is not limited to the examples discussed above.Furthermore, while the various operations described at each of the steps(blocks 102-118) may reference specific components or parts of the CCPP10 based on a determined notification, the operations may be done on anycomponent of the CCPP 10. For example, in the event n notificationregarding the rotor disk 54 is determined, mapping the life odometersolutions, condition monitoring solutions, and the sensors 60, 62, and64 may include mapping related to components of the CCPP 10 other thanthe rotor disk 54. In other words, although n notification maycorrespond to a specific component of the CCPP 10, the life odometersolutions, condition monitoring solutions, and other sensors 60, 62, and64 may be mapped.

Additionally, although not shown, other sensors may be placed in or onother suitable areas or parts of the CCPP 10, and the controller 12 maygenerate an initial maintenance package and/or an updated maintenancepackage 88 at least partially based on the data from the other sensors.For example, while sensors 60, 62, and 64 are temperature sensors,another sensor could be used to monitor the pressure inside a component(e.g., the compressor 22) or for any other purpose that a user findssuitable or desirable. An initial maintenance package and/or an updatedmaintenance package 88 that incorporates data from the other sensor(s)may then be generated.

As can be appreciated by those skilled in the art, the routine forgenerating and/or updating a maintenance package discussed above may beused in conjunction with or applied to any other system or industrialasset that may undergo maintenance such as, but not limited to, anautomobile, an aircraft, an assembly line, or a factory. In other words,the routine for generating and/or updating a maintenance package is notlimited or restricted to being used in relation to a power plant systemor the CCPP 10. Moreover, the routine for generating and/or updating amaintenance package may be executed by any suitable computing device. Inother words, the routine for generating and/or updating a maintenancepackage may be carried out using a processor and memory that areseparate from the controller 12.

Technical effects of the presently disclosed systems and techniquesinclude generating maintenance packages of maintenance operations to beperformed on the CCPP 10 or other suitable industrial equipment.Moreover, providing a maintenance package, the controller 12 may enhancethe performance of the CCPP 10, reduce the downtime of the CCPP 10 usedto perform maintenance, or the like. That is, the amount of maintenanceoperations and time spent performing maintenance on the CCPP 10 may bereduced and the life the CCPP 10 or other suitable system may beextended as a result of the following the maintenance package.

This written description uses examples to disclose various embodimentsof the presently disclosed systems and techniques, including the bestmode, and to enable any person skilled in the art to practice theembodiments, including making and using any devices or systems andperforming any incorporated methods. The patentable scope of thepresently disclosed systems and techniques is defined by the claims, andmay include other examples that occur to those skilled in the art. Suchother examples are intended to be within the scope of the claims if theyhave structural elements that do not differ from the literal language ofthe claims, or if they include equivalent structural elements withinsubstantial differences from the literal languages of the claims.

1. A power plant system, comprising: a turbine system; a sensor configured to collect a first set of data regarding the turbine system; a controller comprising a processor, wherein the controller, via the processor, is configured to: receive user input regarding one or more operating constraints of the turbine system, a second set of data regarding the turbine system from memory, and the first set of data; determine a status of the turbine system based on the first set of data and the second set of data; determine whether a first notification is present based on the status; map one or more life odometer solutions, one or more condition monitoring solutions, and the sensor based on the first notification, wherein the life odometer solutions comprise an expected amount of time before one or more components of the turbine system is repaired, and wherein the condition monitoring solutions comprise one or more conditions of the one or more components; generate a first maintenance package based on the first notification, the life odometer solutions, the condition monitoring solutions, and the first set of data, wherein the first maintenance package comprises one or more maintenance activities for the components; generate a model of implementing the first maintenance package with respect to the turbine system based on the user input, the second set of data, and the first maintenance package; and generate a second maintenance package based on the user input, the second set of data, the first maintenance package, and the model.
 2. The power plant system of claim 1, wherein the first maintenance package or the second maintenance package comprises a maintenance schedule, an operational setting of the power plant system, or a change to a configuration of the turbine system.
 3. The power plant system of claim 1, wherein the controller, via the processor, is configured to determine whether implementing the first maintenance package with respect to the turbine system will remove the first notification based on the model.
 4. The power plant system of claim 3, wherein the controller, via the processor, is configured to: compare the model to a maintenance history of a second turbine system, wherein the maintenance history comprises at least one maintenance operation performed on the second turbine system; and determine whether implementing the first maintenance package with respect to the turbine system will remove the first notification based on the maintenance history of the second turbine system.
 5. The power plant system of claim 1, comprising a maintenance management system, wherein the maintenance management system is configured to implement at least a portion of the second maintenance package with respect to the turbine system or determine an extent to which the second maintenance package has been implemented with regard to the turbine system.
 6. The power plant system of claim 1, wherein the second maintenance package is the same as the first maintenance package.
 7. The power plant system of claim 1, wherein the first set of data comprises information corresponding to the second maintenance package.
 8. The power plant system of claim 1, wherein the controller, via the processor, is configured to generate the first maintenance package based at least partially on a second notification, wherein the second notification is present at the same time as the first notification.
 9. The power plant system of claim 1, wherein the second maintenance package, when implemented, is configured to adjust the first set of data to be within a first threshold, adjust the second set of data to be within a second threshold, or any combination thereof.
 10. The power plant system of claim 1, wherein the controller, via the processor, is configured to: receive a second user input, wherein the second user input comprises a change to the user input; and generate a third maintenance package based at least partially on the second user input.
 11. A method, comprising: receiving, via a processor, user input regarding one or more operating constraints of an industrial asset, a first set of data regarding the industrial asset, and a second set of data from at least one sensor, wherein the second set of data corresponds to a characteristic of the industrial asset; determining, via the processor, a status of the industrial asset based on the first set of data and the second set of data; determining, via the processor, whether a notification is present based on the status; mapping, via the processor, one or more life odometer solutions, one or more condition monitoring solutions, and the at least one sensor based on the notification, wherein mapping the life odometer solutions comprises determining an expected amount of time before one or more components of the industrial asset is repaired, and wherein mapping the condition monitoring solutions comprises determining a one or more conditions of the one or more components; generating, via the processor, a first maintenance package based on the notification, the life odometer solutions, the condition monitoring solutions, and the second set of data, wherein the first maintenance package comprises one or more maintenance activities for the components; generating, via the processor, a model of implementing the first maintenance package with respect to the industrial asset based on the user input, the first set of data, and the first maintenance package; and generating, via the processor, a second maintenance package based on the user input, the first set of data, the first maintenance package, and the model.
 12. The method of claim 11, comprising determining, via the processor, whether implementing the first maintenance package with respect to the industrial asset will remove the first notification based on the model.
 13. The method of claim 11, wherein the second maintenance package is the same as the first maintenance package.
 14. The method of claim 11, comprising generating, via the processor, a second model of implementing the first maintenance package with respect to a second industrial asset.
 15. The method of claim 11, wherein the user input comprises a maintenance budget, and wherein the second maintenance package is predicted to use less of the maintenance budget based on the model and on a second model of the second maintenance package.
 16. A non-transitory machine readable medium, comprising computer executable instructions configured to cause a processor to: receive user input regarding one or more operating constraints of an industrial asset, a first set of data regarding the industrial asset, and a second set of data from at least one sensor, wherein the second set of data corresponds to a characteristic of the industrial asset; determine a status of the industrial asset based on the first set of data and the second set of data; determine whether a first notification is present based on the status; map one or more life odometer solutions, one or more condition monitoring solutions, and the at least one sensor based on the first notification, wherein the life odometer solutions comprise an expected amount of time before one or more components of the industrial asset is repaired, and wherein the condition monitoring solutions comprise one or more conditions of the one or more components; generate a first maintenance package based on the first notification, the life odometer solutions, the condition monitoring solutions, and the second set of data, wherein the first maintenance package comprises one or more maintenance activities for the components; generate a model of implementing the first maintenance package with respect to the industrial asset based on the user input, the first set of data, and the first maintenance package; and generate a second maintenance package based on the user input, the first set of data, the first maintenance package, and the model.
 17. The non-transitory machine readable medium of claim 16, wherein the computer executable instructions are configured to cause the processor to determine whether implementing the first maintenance package with respect to the industrial asset will remove the first notification based on the model.
 18. The non-transitory machine readable medium of claim 16, wherein the second maintenance package comprises a planned outage, a maintenance outage, or a forced outage for the industrial asset.
 19. The non-transitory machine readable medium of claim 16, wherein the first set of data comprises a maintenance history of the industrial asset.
 20. The non-transitory machine readable medium of claim 16, wherein the computer executable instructions are configured to cause the processor to generate the first maintenance package based at least partially on a second notification, wherein the second notification is present at the same time as the first notification. 